Carton opening apparatus and method



June 27, 1961 w. H. WILCOX CARTON OPENING APPARATUS AND METHOD 4Sheets-Sheet 1 Filed July 50, 1958 l lll INVENTOR. WILL/AM H. W/LCOX A7' TO/PNEVS June 27, 1961 w. H. wlLcox 2,989,903

CARTON OPENING APPARATUS AND METHOD Filed July 30, 1958 4 Sheets-Sheet 2FIG. 4

INVENTOR. WILL/AM h. W/L COX A TTO/PNEVS June 27, 1961 w. H. WILCOX2,989,903

CARTON OPENING APPARATUS AND METHOD Filed July 30, 1958 4 Sheets-Sheet 3FIG. 8

INVENTOR. W/LL/AM H. W/LCOX A T TO/PNEVS June 27, 1961 w. H. WILCOXCARTON OPENING APPARATUS AND METHOD 4 Sheets-Sheet 4 Filed July 50, 1958INVENTOR. WILLIAM H. WILCOX A TTORNEVS United States Patent 2,989,903CARTON OPENING APPARATUS AND METHOD William H. Wilcox, Stockton, Caiifi,assiguor to Fibreboard Paper Products Corporation, San Francisco,Calif., a corporation of Delaware Filed July 30, "1958, Ser. No. 751,98716 Claims. (Cl. 93-53) This invention relates generally to an apparatusand method for erecting and opening cartons from a collapsed state. Moreparticularly this invention relates to an apparatus and method forautomatically removing individual collapsed cartons from a cartonsupply, positioning such individual cartons on a supporting surface andthereafter moving the individual cartons past structure intended toperform a series of operations thereon to transform the cartons from thecollapsed state to the fully opened or erected tubular state so thatproduct may be inserted into the cartons thus erected.

Desirably the apparatus of the present invention is divided into aplurality of longitudinally aligned discrete sections, each of whichextends at a predetermined angle of inclination relative to the othersections of the apparatus. By providing the apparatus with such discreteinclined sections, the carton opening operation is facilitated and themethod employed is simplified.

According y, the objects of the present invention, among others, includethe provision of an apparatus for automatically and continuously feedingcollapsed cartons from a carton supply and transporting cartons thus fedinto engagement with structure intended to perform operations on thecartons until the same are transformed from the collapsed state to theerected open ended tubular state; the provision of a method foreffecting such carton erecting operations; the provision of means fordeflecting a carton closure flap to facilitate closure flap separation;the provision of means to maintain separation of the remainder of thecarton closure flap from the deflected flap; the provision of cartonsupporting surfaces in said apparatus which are inclined relative toeach other to facilitate flap separation and carton setting up; and theprovision of means for transporting cartons from one position in theapparatus to another during the setting up operation.

These and other objects will become evident from reading the followingdescription, in which reference is directed to the accompanying drawingswhich illustrate one desirable embodiment of the carton openingapparatus.

FIG. 1 is a plan view of a collapsed carton of a type adapted to beopened by the apparatus of this invention;

FIG. 2 is an isometric view of an open end of an erected carton ready toreceive product therein;

FIG. 3 is a schematic isometric view of a desirableembodiment of thecarton erecting apparatus of this invent-ion;

FIG. 4 is a side elevation of part of the apparatus showing means forfeeding collapsed cartons from a supply and placing the same on a cartonsupporting surface;

FIG. 5 is a side elevation of part of the apparatus illustrating meansfor transferring the cartons from adjacent the carton supply to a flapdeflecting means;

FIG. 6 is a side elevation of part of the apparatus illustrating meansfor deflecting a major flap of the carton to facilitate flap separation;

FIG. 7 is a view similar to FIG. 6 showing the deflected carton flapbeing separated from the remainder of the carton flap by means designedfor that purpose;

FIG. 8. is a plan view of that part of the apparatus shown in FIG. 6;

FIG. 9 is a plan view of that part of the apparatus shown in FIG. 7;

2,989,903 Patented June 27, 1961 FIG. 10 is a side elevation of meansfor conveying a carton through a section of the apparatus;

FIG. 11 is a side elevation of means effective to set up a carton;

FIG. 12 is a side elevation which corresponds substantially to FIG. 11and illustrates the final steps of the carton setting up operation;

FIG. 13 is a vertical section taken in the plane of line 13-43 of FIG. 7illustrating the relationship between the conveyor means and the cartonflap deflecting and separating means of the present apparatus;

FIG. 14 is a schematic view illustrating the inclination of individualsections of the apparatus relative to each other.

It has been known in the art heretofore to position a plurality ofcartons in set up open ended condition on a conveyor and to move thesame past a supply of product to be filled in the respective cartons.However, difliculty is often encountered in automatically erecting thecartons prior to their positioning on the conveyor for reception of theproduct intended to be packaged therein. The apparatus of this inventionwas devised to facilitate erecting of cartons from the collapsed statefor receiving product.

Generally, cartons of the type here involved are formed from flexiblematerial, such as paper board, and are of the type intended to packagevarious products, 1such as cakes produced in a commercial bakery or theuse.

Such paperboard cartons generally are fabricated by the manufacturerinto a flattened or collapsed tubular configuration havinglongitudinally extending closure flaps at opposite ends thereof. Suchcartons are shipped to the user in the collapsed state to conservespace. It thereby becomes necessary for the carton user to erect thecartons so that the same may be filled with the desired product for saleto the ultimate consumer. However, difiiculty often is encountered inthe carton setting up operation in that not infrequently the cartons cannot be transformed rapidly from the collapsed tubular state to theerected open tubular state without damaging the cartons.

The present invention is directed to an apparatus which automaticallyfeeds collapsed tubular cartons from a carton supply and automaticallyand continuously transforms the same without damage to open tubularstate at high speeds compatible with the speeds employed by availablemachinery for inserting product into open cartons.

Although the apparatus of this invention and the carton erecting methodperformed thereby may be utilized with cartons of variousconfigurations, such apparatus is designed primarily for opening cartonsof the type illustrated in FIGS. 1 and 2. Such cartons are designated 1and generally comprise a plurality of body walls, such as 2, 3, 4 and 6,which are hingedly connected together into an annularly continuoustubular configuration in any suitable rnanner. Such body walls may haveany suitable dimensional relationship, but in the embodimentillustrated, opposite walls 2 and 4 are of a width somewhat greater thanthe width of body walls 3 and 6. All of such wflls have equal length,however. In the collapsed condition shown in FIG. 1, body walls 4 and 6underlie and are in contact with the inner surfaces of body walls 2 and3.

Hingedly connected to the collapsed carton at opposite ends thereof arecarton closure means in the form of opposite cooperable pairs of endclosure flaps which are intended to seal the ends of the carton afterthe same has been filled with its intended product. Corresponding flapsat opposite ends of the cartdn generally are identical and, accordingly,the flaps at only one carton end will be 3 specifically described anddiscussed herein. However, similar flaps at the opposite carton end havebeen identified by similar reference numerals primed.

Hingedly connectedto the. margin of each of. large body walls 2 and 4are upper and lower major closure flaps 7 and 8. A pair of minor sideclosure flaps 9 and 11' are hingedly connected to margins of oppositesmall side body walls 3 and 6. When the carton is collapsed as shown inFIG. 1, upper major flap 7 and upper minor flap 11 overlie and contactthe inner faces of lower major flap 8 and lower minor fiap 9.

Minor flapsf9 and 11 are of substantially less length than major flaps 7and 8 so that the outer free edges of flaps 7 and 8 extendlongitudinally of the carton beyond the outer free edges of; minor flaps'9 and 11. This arrangement is illustrated by the erected carton shownin FIG. 2.

Cartons of the type described may be utilized for packaging variousproducts, such as, for example, cakes produced in a commercial bakery orthe like. Such cakes generally are produced in large quantities andapparatus for automatically packaging such cakes at a high rate of speedis highly desirable so that the same may be submitted to the buyingpublic as soon after baking as possible. Accordingly, high speed cartonsetting up apparatus is required for use with existing high speedmachinery which :is adapted to automatically insert cakes or the likeinto fully open cartons.

The overall apparatus of this invention is designed to transform cartonsfrom the collapsed tubular state shown in FIG. 1 to the open endederected tubular state shown in FIG. 2. Such apparatus may take variousform but the illustrated embodiment includes a collapsed carton supplyhopper 16 of any suitable design in which a supply of collapsed cartons1 is positioned. In the embodiment illustrated, hopper 16 is positionedabove the apparatus, but such hopper may be located in any convenientposition relative to the apparatus.

The carton apparatus itself is divided longitudinally into three majorsections, designated A, B and C for purposes of identification. (SeeFIGS. 3 and 14.) Desirably, each of these sections is a substantiallongitudinal continuation of the other with each of such sections beinginclined at a predetermined angle relative to an adjacent section.Desirably, although not necessarily, the carton supporting surface ofsection C extends in a substantially horizontal plane with the cartonsupporting surfaces of sections B and A being inclined different amountsrelative to the horizontal.

The carton supporting surface of each section is defined by a pair ofparallel rails 17 and 18 which extend longitudinally of the apparatus.The upper surfaces 19 and 21 of the respective rails in each sectiondesirably are substantially flat and lie in a common plane to provide asmooth surface over which cartons may be moved. In the illustratedembodiment, rails 17 and 18 are continuous and extend throughout each ofthe sections comprising the apparatus. However, separate pairs of railsmay be employed in each apparatus section to facilitate fabrication ifso desired.

Points or areas or locations of transition are provided along the lengthof rails 17 and 18 at which the inclination of the rails relative to areference plane, such as the horizontal, changes to define the separateapparatus sections. These points or areas or locations of angulartransition serve as junctions between adjacent sections. While in theembodiment of the apparatus illustrated, three such distinct sectionsare provided, it should be understood that under certain circumstancesmore than three or less than three sections may be utilized to meet aparticular need or perform a given function.

Taking reference to FIG. 14, it should be understood that as a collapsedcarton passes from one inclined section to another, for example, fromsection A to section B, the leading edge of the carton will lie in onesection while 4 the trailing edge thereof will lie in another section.Such a situation tends to cause the central portion of the carton torise up out of contact with the supporting rails. It is to produce sucha situation that the inclined sections were devised so that cartonerecting could be facilitated, as Will be set out hereinafter.

Mounted adjacent one end of the apparatus for movement relative to thesupply hopper 16 is feeder means 22 (FIGS. 3-5) adapted to withdrawindividual collapsed cartons from the hopper and position the same onthe supporting surface defined by rails 17 and 18 of section A of theapparatus. Such feeder means 22 desirably takes the form of a pluralityof suction cups 23 positioned between rails 17 and 1 8 for reciprocationin an arcuate path relative to the apparatus and carton hopper 16.

The suction cups 23 may be mounted for rotation between rails 17 and 18in anysuitabie manner and may be reciprocated by any suitable means,suchas a crank or cam arrangement (not shown) which will move the cups fromthe lower retracted position shown in FIGS. 3 and 4 to the extendedcarton engaging position shown in FIG. 5 wherein the outermost carton inthe hopper may be withdrawn from the hopper. Any suitable means may beincorporated with the hopper to insure that only one carton is withdrawnat a time.

While suction cups have been found to be a suitable means for feedingindividual cartons from the hopper, various other means known in the artalso could be utilized Cartons Withdrawn by feeder means 22 from thehopper are carried downwardly through a substantially arcuate path, andare positioned on the upper surfaces 19 and 21 of rails 17 and 18transversely thereof with the carton closure flaps extending laterallybeyond the rails. When in such position, suction cups 23 are disengagedautomatically from the carton, and the same is free to be movedlongitudinally along section A of the apparatus.

For effecting such' longitudinal movement, transfer means is provideddesirably in the form of a pair of reciprocable bell cranks 24 and 26,which are positioned outboard of rails 17 and 18, respectively, andwhich are intended to reciprocate in planes extending substantiallyparallel thereto. Each bell crank 24 and 26 is substantially identical,as is the mechanism for actuating each bell crank. Accordingly, onlybell crank 24 adjacent rail 17 and the mechanism for reciprocating thesame will be specifically described. It should be understood, however,that bell cranks 24 and 26 operate in unison to move cartons frombeneath hopper 16. Similar reference numerals primed are used toidentify similar parts of bell crank 26 and its operating mechanismrelative to bell crank 24.

Bell crank 24 is mounted for pivotal movement relative to rail. 17 mmincludes a pusher arm 27 terminating in a carton engaging head 28 at itsupper end. "Bell crank 24" is mounted for movement about pivot pin 29which extends through rail 17 adjacent the bottom thereof. The other'arm31 of bell crank 24 is pivotally connected to any suitable actuatingmeans for effecting reciprocation of pusher arm 27 relative to cartonspositioned on rails 17; In the embodiment illustrated, such actuatingmeans takes the form of a push rod 32 connected 'at one end thereof bypivot pin 33 to arm'3-1 of bell'c'rank 24 and at its opposite end to acam wheel or sprocket 34 by means of pivot pin 36.

Push rod 32 is eccentrically connected to sprocket 34 so that rotationof the sprocket will resultin a back and forth movement of hell crank 24about pivot pin 29 in a well known manner. Rotationof sprocket 34 may beeffected in any suitable manner. a

1n the embodiment illustrated, sprocket'34 is mounted for rotation withan axle 38 which extends between and through rails 17 and 18. It'should.be remembered that a similar bell crank sprocket arrangement also. isconnected toaxle 38 outboard ofrail 18.. Upon rotation of sprocket 34 byaxle 38, push rod 32 actuates bell crank 24 so that the samereciprocates about pivot pin 29 between the retracted and advancedpositions shown in FIGS. 4 and 5, respectively. Movement of bell crank24 results in a carton being pushed down the inclined supporting surfaceof section A toward the inclined supporting surface of section B.

FIGS. 4 and 5 also illustrate the timed relationship which existsbetween movement of the feeder means 22 and the transfer meanscomprising bell cranks 24 and 26 of the present apparatus. As shown inFIG. 4, when suction cups 23 withdraw a carton from the hopper andposition the same on top of rails 17 and 18, bell cranks 24 and 26 arein the retracted position. After the car ton has been released bysuction cups 23 the bell cranks move the carton down the inclinedsurface of section A. When the carton clears the suction cups, thesuction cups may again be moved without interference to the upperposition shown in FIG. 5 to withdraw another carton. The operationsperformed by the bell cranks and suction cups are so timed that cartonsmaybe withdrawn from the hopper and moved along the rails at a high rateof speed.

In this connection, suction cups 23 may be mounted for reciprocationrelative to rails 17 and 18 in any suitable manner. One such suitablemanner is shown in FIGS. 4 and 5 wherein the cups are pivotally mountedon the same axle 38 upon which sprocket 34 is mounted. It should beunderstood, however, that the suction cups are merely mounted forrotation relative to the axle, but are not driven thereby. Independentmeans of any suitable type may be utilized to efiect reciprocation ofthe suction cups about axle 38.

The apparatus of the present invention also includes means, desirably inthe form of first endless conveyor chain 41, intended to move a cartonfrom engagement with heads 28 and 28' of the bell cranks 24 and 26andfrom section A of the apparatus to and along section B thereof. Chain 41is positioned to run over and between sprocket 34 and a cooperatingsprocket 42 spaced therefrom (see FIG. 3) outboard of rail 17. Suitableteeth are provided about the peripheries of such sprockets. A pluralityof spaced carton engaging lugs 43 are fixedly secured to endless chain41 for movement therewith. A similar chain-lug arrangement is providedin conjunction with rail 18, and is designated 41, 43.

Each of the lugs is intended to engage any suitable trailing portion ofa carton positioned on rails 17 and 18 for moving the same from the endof section A of the apparatus through section B thereof. In theembodiment illustrated, the lugs engage the trailing edges of the bottommajor flaps 8 and 8' of the canton as best shown in FIGS. 7, and 11.

Because sprocket 34 is positioned beneath section A of the apparatus inthe area of angular transition between inclined sections A and B (seeFIGS. 6 and 7), each chain lug comes up underneath the carton as thesame moves from section A to section B. This is so because, aspreviously noted, the central portion of the carton rises slightly offrails 17 and 18 as it passes through the area of angular transition ofthe rails. Accordingly, lug 43 engages the trailing edge of major flap 8and holds minor flap 9 slightly out of the plane of major flap 8. Thisengagement of lug 43 with flap 8 is facilitated in that flap 8 isdeflected downwardly as the carton reaches the transition point betweensections A and B.

Desinably, heads 28 and 28' of bell cranks 24 and 26 remain inengagement with the carton until the conveyor chain lugs are firmly andproperly engaged with flaps 8 and 8 (note FIG. 7).

The present apparatus includes means for deflecting the major closureflaps 8 and 8' downward-1y away from the remainder of the closure flapsat each end of the carton so that the flaps may be separated from eachother to facilitate the carton erecting operation. In the embodimentillustrated, the flap deflecting means comprises a defleeting member inthe form of an elongated slender tubular or the like cleavage finger 44positioned outboard of rail 17 and mounted on the apparatus so that itsleading portion or end 45 is positioned in substantial alignment withthe location of angular transition of the rails from the angle ofinclination of section A to the lesser angle of inclination of sectionB. Member 44 is mounted on the apparatus by means of any suitablebracket 46. A similar deflecting member is mounted outboard of rail 18to deflect flap 8' of the carton.

As collapsed carton 1 is moved along section A towards section B by thetransfer and conveyor means described, the leading edge of underlyingmajor flap 8 of the carton 1 passes beneath leading end 45 of member 44.Because of the inclination of the carton resulting from the inclinationof section A, member 44 may more easily be engaged with the uppersurface of flap 8. Also, as noted previously, movement of the cartonfrom section A to section B results in the leading and trailing edges ofthe carton being positioned on rail sections extending at differentangles relative to each other, thereby causing the central portion ofthe carton to lift ofl the rails in the area of angular transitionbetween the sections. Such tendency of the central portion of the cartonto lift automatically results upon continued movement of the carton inthe underlying major flap 8 being bent down by deflecting member 44 outof the plane of its associated carton body wall 4. This situation isillustrated in FIGS. 6 and 7.

As noted previously, lug 43 on chain 41 comes up beneath the carton andengages only the trailing edge of underlying major flap 8. Thepositioning of sprocket 34 relative to deflecting member 44 results inlug '43 engaging flap 8 just as the flap is deflected. Thereafter, bellcranks 24 and 26 retract and the carton is moved solely by the conveyorchain 41.

As shown in FIGS. 8 and 9, deflecting member 44 is mounted or positionedoutboard of conveyor chain 41 so that the deflecting member will notinterfere with the conveying function of lug 43. Furthermore, deflectingmember 44 is so arranged that it initially contacts only the upper faceof lower major flap 8 Without contacting minor flap 11 (see FIGS. 6 and8).

In this connection, it should be understood that if an attempt were madeto insert the deflecting member 44 between the leading edges of minorflap 11 and major flap 8, such operation would be extremely difficultwithout destroying or damaging the flaps. This is so because minor flap11 of the collapsed carton overlies and is in contact with underlyingmajor flap 8 throughout its entire extent. Therefore, no separatingmember could be inserted between the two flaps at the high speedsrequired to make a carton opening apparatus commercially practicalwithout damaging the carton.

As a result, because of the shorter length of minor flap 11 relative tounderlying major flap 8, flap deflecting member 44 may be engaged withflap 8 without contacting or damaging minor flap 11. As shown in FIG. 7,upon movement of the carton by lug 43 relative to stationary deflectingmember 44, major flap 8 is deflected downwardly relative to the threeremaining closure flaps and is completely separated therefrom. It shouldbe understood that the deflection of lower major flap 8 by member 44 isenhanced and facilitated because of the angular difference existingbetween the supporting surfaces of section A and section B. Furthermore,such angular difference results in the central portion of the cartonrising ofl the rails and such central portion carries upper major flap 7therewith. As a result, flap 7 and flap 8 are separated and deflectingmember 44 may enter therebetween.

Continued movement of the carton along section B results in completeisolation and separation of major flap 8 from the remaining flaps at thecarton end.

To eflect complete separation of closure flap 8 from the remainingclosure flaps 7, 9 and 11 and maintain such separation so that thecarton may be automatically set up, means is provided desirably in theform of an elongated metal band 47 having a leading end 48 thereofpositioned adjacent the trailing end of deflecting member 44. Ifdesired, deflecting member 44 and band 47 could be formed as a singleelongated member, but desirably band 47 and member 44 are formed asseparate parts as illustrated to facilitate fabrication thereof.

The lea-ding end 48 of separating band 47 is positioned in substantialalignment with the trailing end of deflecting member 44. As a result,movement of a carton through the apparatus results in leading end 48 ofband 47 also entering between lower major flap 8 and upper major flap 7.However, as illustrated in FIGS. 8, 9 and 13, the major portion of band47 lies inboard of chain 41 and a thin curved portion 49 connectsleading end 48 to the major portion of band 47.

Upon deflection of lower flap 8 by deflecting member 44, a space isprovided betwen the leading edges of upper minor flap 11 and lower majorflap 8 (see FIGS. 6 and 7). The inner edge of the curved portion 49 ofband 47 is comparatively thin, such as a knife edge, and as the cartonis moved by conveyor lug 43, such edge is free to enter the spacebetween flaps '11 and 8 and separate the same (note FIG. 13). It shouldbe understood that the edge of band portion 49 can easily enter betweenflaps 11 and 8 because flap 8 has first been deflected downwardly bymember 44.

Continued movement of the carton results in band 47 being insertedbetween lower major flap 8 and the remaining three flaps 7, 9 and 11.This is so because defleotion of flap 8 also results in a space beingprovided between the trailing edge thereof and the leading edge of lowerminor flap 9 (FIG. 7). It is into such space that the edge of bandportion 49 is positioned in the same manner as the band was positionedbetween flaps 11 and 8., This condition of the canton with flap 8 helddown by band 47 and separated from flaps 7, 9 and 11 is shown in FIG.10.

As illustrated in FIGS. 6, 7 and 13, the curved portion 49 of band 47 isupwardly bowed a predetermined distance to provide a clearance space sothat lugs 43 of conveyor chain 41 may pass beneath the separating bandwithout contacting the same.

After lower major flap 8 has been separated from the remainder of theclosure flaps, the carton is ready to be erected to the fully openedtubular condition illustrated in FIG. 2. Such canton erecting may beeffected by means of a second conveyor arrangement in combination with asuitable plow member. Such second conveyor desirably includes an endlesschain 50 (FIGS. 3, 11 and 12) positioned inboard of rail 17 and havingmounted thereon a plurality of spaced carton set up lugs 51. Chain 50 ismounted on sprocket wheel 52 positioned on the same axle 53 on whichsprocket 42 of the first conveyor means is mounted for rotation. In thismanner, each conveyor may be actuated in timed relationship by a commonpower source. It should be understood that a similar conveyor chain 50'carrying set up lugs 51' is positioned inboard of rail 18 and alsorotates about sprocket 52' on axle 53.

As shown in FIGS. 3 and 11, sprockets 52 and 52' are positioned adjacentthe area of transition between sections B and C of the apparatus. As aresult, when the canton is transferred by lugs 43 of the first conveyortoward section C, and as the leading edge of such carton reaches sectionC while the trailing portion thereof is still supported on section B,the central carton portion again tends to rise from the spaced rails 17and 18. However, the carton as a whole is generally held down on therails by means of the elongated separating bands which engages the lowermajor flaps 8 and 8'.

As shown in FIG. 11, when the carton reaches the transition pointbetween sections B and C, the set up lugs 51 and 51 of the secondconveyor means come up behind and engage the trailing end of the cartonand tend to urge the same to the upright position. As noted in FIG. 12,desirably the set up lugs are of a length slightly greater than theheight of side body walls 3 and 6 of the carton.

Because the carton is substantially held down by the separating band 47,the carton can not be moved from contact with the rails 17 and 18.Therefore, as a result of flap 8 being separated from the remainder ofthe flaps, the carton is automatically set up as lugs 51 and 51 engagethe same, as illustrated in FIGS. 11 and 12.

However, because at this stage in the setting up operation a portion ofthe carton lies on each of sections B and C, there is a possibility ofthe carton buckling as force is applied to the trailing edge thereof bythe set up lugs. To preclude such buckling, plow members 54 and 54 areprovided on top of separating bands 47 and 47' (FIGS. 3, 1'1 and 12)which engage upper major flaps 7 and 7 and move the same upwardly sothat buckling of the carton is precluded, and automatic setting upthereof is insured.

Upper band members 55 and 55 are provided for use in conjunction withplow members 54 and 54' and are adapted to ride beneath flaps 7 and 7'of the carton to cooperate with set up lugs 51 and 51 in maintaining thecarton open to allow insertion of the product into the carton. As aresult, as shown in FIG. 12, the fully erected carton is conveyed alongsection C of the apparatus by the set up lugs 51 and 51 of the secondconveyor means with lower band 47 maintaining lower major flap 8 openand upper band 55 underlying and maintaining upper major flap 7 open.

While plow members 5-4 and 54 will temporarily deflect respective minorflaps 9, 9', 11 and 11' as the same come in contact with the plows, asthe carton moves beyond the plow, such minor flaps are free to snap backto the straight out extended position shown in FIG. 3.

Desirably, bands 47 and 55 are provided along their extent with meansfor deflecting major flaps 7 and 8 upwardly and downwardly respectivelyfrom the horizontal so that the mouth of the carton is substantiallyunrestricted during the filling operation. Such means, as shown in FIG.3, may take the form of angle sections 56 secured to the bands beyondplow 54. Other suitable arrangements also may be employed.

After the cartons have been fully opened as described, the same arecarried by the lugs of the second conveyor past any suitable means forinserting a product into each of the cartons and thereafter pastsuitable means for defleeting inwardly the closure flaps to seal thecarton and maintain the product therein. Mechanisms for automaticallyloading product into open cartons and for thereafter sealing the cartonsare well known. Any such mechanisms may be utilized with the cartonopening apparatus of this invention. It should be understood that thetype of closure provided for the cartons may vary, depending upon theproduct packaged therein.

From the foregoing, it should be understood that the apparatus of thepresent invention provides means for automatically and rapidly feedingcartons from a supply, erecting the same from the flattened state andcompletely opening the ends thereof so that product may be insertedtherein without interference from the closure flaps of the carton. Itshould further be understood that the various components of theapparatus are driven in timed relationship relative to each other toinsure a steady, smooth, continuous flow of cartons through theapparatus without interrupted motion.

.As mentioned previously, an important feature of this invention residesin the fact that the carton supporting surfaces of sections A, B and Care each inclined relative to each other. While the exact angles ofinclination of the respective surfaces are not critical, a suitable andsatisfactory arrangement is obtained if the carton supporting surface ofsection \C extends substantially horizontally. This facilitates productinsertion in that the product may be inserted into the cartons in ahorizontal direction. This factor is important if the product is a cakeor similar bakery goods. 7

The suitable relationship above mentioned includes positioning thesupporting surface of section B so that it is inclined upwardly atapproximately 7 relative to the surface of section C with the supportingsurface of section A inclined upwardly at approximately 10 relative tothe surface of section B. That is, a suitable arrangement is obtained ifsection C is horizontal, section B is inclined upwardly at 7 relative tothe horizontal and section A is inclined upwardly at 17 relative to thehorizontal.

This particular angular relationship, while generally satisfactory, maybe varied to solve a particular problem relative to a particular typecarton.

Because this apparatus is intended for use with various types and sizesof cartons, desirably the components thereof are adjustable so that suchvarious cartons may be accommodated. For example, bands 55 and 55 may bevertically adjusted relative to bands 54 and 54'. Other cooperablecomponents of the apparatus also may be adjusted relative to each other.

While one embodiment of the invention has been described herein, othermodifications Which may become apparent to one skilled in the art, alsoare part of the invention and the same should be interpreted in light ofthe appended claims.

-I claim:

1. Apparatus for deflecting a closure flap of a carton away from otherclosure flaps of said carton comprising first and second cooperablecarton supporting surfaces, said first surface being inclined at apredetermined angle relative to said second surface, means for movingsaid carton continuously over said first surface and withoutinterruption onto said second surface, and means fixedly and immovablypositioned adjacent a location of angular transition between saidsurfaces for engaging and automatically deflecting said closure flapaway from said other closure flaps as said carton is moved by saidmoving means from said first surface to said second surface.

2. Apparatus for transforming a carton having a plurality of closureflaps at an end thereof from the collapsed state to the open endederected state comprising substantially longitudinally aligned first andsecond carton supporting surfaces, said first surface being inclined ata predetermined angle relative to said second surface, and means fordeflecting one closure flap away from the remainder of said closureflaps comprising a flap deflecting member having a leading portionthereof fixedly and immovably positioned adjacent a location of angulartransition between said surfaces whereby said one closure flap ispositioned beneath said member and is automatically deflected therebyaway from the remainder of said closure flaps as said carton is movedcontinuously along said first surface and without interruption onto saidsecond surface.

3. Apparatus for opening a collapsed carton having closure flaps at anend thereof comprising means for moving said carton continuously andwithout interruption over a first carton supporting surface and a secondcarton supporting surface which extends at a predetermined anglerelative to said first surface, means for deflecting and separating aclosure flap from other of said closure flaps including a flapdeflecting member fixedly and immovably positioned adjacent a locationof angular transition between said first and second surfaces and acooperable flap separating band extending away from said transitionlocation toward a third carton supporting surface which extends at apredetermined angle relative to said second surface, and continuouslymovable carton erecting means engageable with said carton as the samereaches said third surface, said erecting means being cooperable withsaid separating band to automatically transform said carton from acollapsed state to an open ended erected state without interruptingmovement of said carton so that the contents intended for said cartonmay be inserted therein.

4. Apparatus for removing an individual collapsed carton having at anend thereof opposite pairs of major and minor end closure flaps from asupply of collapsed cartons and transforming the same to open endederected state, comprising feeder means for withdrawing said carton fromsaid supply and positioning the same on a first carton supportingsurface, means operable in timed relationship with said feeder means formoving said carton continuously and without interruption along saidfirst surface and onto a second carton supporting surface provided as asubstantial continuation of said first surface, immovable deflectingmeans positioned adjacent a junction of said first and second surfacesand engageable with one of said major flaps for deflecting the same awayfrom the remainder of said flaps, means extending along said secondsurface and engageable over said one major flap for separating said onemajor flap from the remainder of said flaps and holding down the same,said carton being movable continuously and without interruption by saidmoving means along said second surface to a third carton supportingsurface provided as a substantial continuation of said second surface,carton erecting means movable continuously and without interruptionrelative to said third surface in timed relationship relative to saidmoving means and being initially engageable with said carton adjacent ajunction of said second and third surfaces, said erecting means beingengageable with said carton only externally thereof and cooperable withsaid flap separating means in transforming said collapsed carton to saiderected state, said first, second and third surfaces being substantiallylongitudinally aligned with each other with the planes of said first andsecond surfaces being inclined relative to each other and with each ofsaid planes being inclined relative to the plane of said third surfacewhereby deflecting said one major flap, separating the same from theremainder of the flaps and erecting said carton is facilitated.

5. The apparatus of claim 4 wherein each of said first, second and thirdsurfaces is defined by a pair of spaced rails.

6. The apparatus of claim 4 wherein said third surface extends in asubstantially horizontal direction, said second surface extends upwardlyat a predetermined angle relative to the horizontal and said firstsurface extends upwardly at a predetermined angle relative to saidsecond surface.

7. Apparatus for transforming a carton having a pair of major closureflaps and a pair of minor closure flaps at an end thereof from thecollapsed state to the erected state, comprising first and second cartonsupporting surfaces inclined relative to each other, means engageablewith said carton for moving. the same continuously along said firstsurface and without interruption onto said second surface, a flapdeflecting finger fixedly and immovably mounted in the path of movementof said major flaps at the point of angular transition between saidfirst and second surfaces and out of the path of movement of said minorflaps whereby one major flap is engageable beneath said deflectingfinger and is deflectable thereby away from the other major flap andsaid minor flaps as said carton is moved from said first surface ontosaid second surface thereby providing a clearance space therebetween; aseparating band having an end aligned with said deflecting finger, anintermediate curved section positioned across the path of movement ofsaid minor flaps, and a trailing section in the path of movement of saidminor flaps and extending along said second surface whereby said band isinsertable into the clearance space between the deflected major flap andthe other major flap and said minor flaps and held down thereby duringcontinued movement of said carton along said second surface; andcontinuously movable means engageable with a trailing portion of saidcarton for urging said 1 1 carton 'to the erected position while thedeflected major flap is held down by said separating band.

8. The apparatus of claim 7 including a plow device positioned in thepath of movement of said major and minor flaps to preclude buckling ofsaid carton as the same is erected by said movable means engageable withsaid carton trailing portion.

9. Apparatus for transforming a carton from a collapsed state to anerected open ended state, said carton comprising a body having at an endthereof a pair of minor end closure flaps and a pair of major endclosure flaps which extend beyond outer edges of said minor flaps, saidcarton when in said collapsed state having one minor flap and one majorflap overlying the other minor and major flaps, said apparatuscomprising a supporting surface over which said carton is movable withsaid major and minor flaps extending laterally beyond said supportingsurface, said supporting surface comprising two distinct sections one ofwhich is angularly inclined upwardly relative to the other, the othersurface section being a substantial continuation of said one section andoperatively meeting the same at a location of angular transition betweensaid sections, mechanism for moving said carton along and from said onesection onto and along said other section with said underlying majorflap in leading relationship, and means positioned adjacent saidlocation of angular transition for separating said underlying major flapfrom the remaining flaps of said carton and for positively holding downthe same so that said carton may be erected; said flap separating andholding down means comprising a flap deflecting member mounted outboardof said surface sections a distance sufficient to contact said majorflaps and to clear said minor flaps when said carton is moved therepast,and a flap hold down band extending along said other surface sectioninboard of said deflecting member, said underlying carton major flapbeing automatically positioned beneath said deflecting member when saidcarton is moved from said one surface section onto said other sectionwherebysuch flap is positively separated from all the remaining cartonflaps and whereby the carton may be held down by said band engaging thethus separated flap as carton movement is continued.

10. The apparatus of claim 9 including carton erecting means engageablesolely with the exterior of said carton for effecting carton erectionwhereby the need for inserting an erecting member into said carton toeffect erection thereof is precluded, said erecting means comprising amovable member engageable with a trailing portion of said carton whilesaid underlying major flap is held down by said band, said movablemember being cooperable primarily with said hold down band in effectingcarton erection.

11. The apparatus of claim 10 in which said carton supporting surfaceincludes a third section which is angularly related to said othersupporting surface section, said movable member being initiallyengageable with said carton adjacent the location of angular transitionbetween said other surface section and said third section.

12. The apparatus of claim 11 which includes means for precludingbuckling of said carton while the same is being erected and formaintaining the carton end open and free of restriction by said pairs offlaps after erection to permit filling of product therein.

13. A method of separating a single closure flap from other closureflaps of a carton having opposite pairs of major and minor closure flapsat an end thereof, comprising moving said carton in a firstpredetermined path with one major flap and one minor flap underlying theother major and minor flaps and with said underlying major flap inleading relationship during carton movement, positioning a flapdeflecting member adjacent said first carton path at a location tocontact said major flaps and to clear said minor flaps, changing thedirection of movement of said carton from said first predetermined pathto a second predetermined path which is angularly related to said firstpath as said carton approaches said deflecting member, engaging saidleading underlying major flap beneath said deflecting member as saidcarton moves from said first path into said second path whereby suchflap is deflected by said member away from the remaining flaps of saidcarton, and moving said carton along said second predetermined path andmaintaining said deflected flap separated from the remaining flaps ofsaid carton.

14. The method of claim 13 including providing a flap separating bandalong said second predetermined path of carton movement, and insertingsaid separating hand between said deflected underlying major flap andthe remainder of said closure flaps whereby said underlying flap is helddown by said band as said carton moves along said second path.

15. A method of transforming a carton having opposite pairs of major andminor end closure flaps at an end thereof from the collapsed state tothe erected open ended state, comprising moving said carton in a firstpredetermined path with one major flap and one minor flap underlying theother major and minor flaps and with said underlying major flap inleading relationship during carton movement, positioning a flapdeflecting member adjacent said first carton path at a location tocontact said major flaps and to clear said minor flaps, changing thedirection of movement of said carton from said first path to a secondpredetermined path which is angularly related to said first path as saidcarton approaches said deflecting member, engaging said leadingunderlying major flap beneath said deflecting member as said cartonmoves from said first path into said second path whereby such flap isdeflected by said member away from the remaining carton flaps,maintaining said deflected major flap separated and held down and awayfrom said remaining flaps as said carton is moved along said secondpath, and engaging and urging forwardly a trailing folded edge portionof said carton as said deflected flap is held down to effect erection ofsaid carton without inserting any erecting mechanism into said cartonduring erection thereof.

16. The method of claim 15 including moving said carton from said secondpath into a third predetermined path which is angularly related to bothsaid first and second paths as said carton trailing edge is urgedforwardly to facilitate erection thereof, and precluding buckling ofsaid carton as the same moves from said second path into said thirdpath.

References Cited in the file of this patent UNITED STATES PATENTS Re.24,668 Rodman July 21, 1959 2,009,828 Wild July 30, 1935 2,068,163Bowersock et al. Jan. 19, 1937 2,750,856 Ferguson et al. June 19, 19562,906,392 Galloway Sept. 29, 1959

